Carton And Method Of Making Same

ABSTRACT

Disclosed is a carton and a method for forming the carton from a single construction. A sheet of material is processed to form a blank with apertures. The blank is folded to form panels that make up the walls and lid of the carton. A rack is formed with slots and apertures to secure contents within the carton.

BACKGROUND

Syringes are used by the medical community to inject medication into patients. Syringes generally have a hollow elongated barrel engaged by a plunger, a needle tip and a handle. Syringe barrels are often made of glass or plastic, and thus are not immune to breakage. Syringes may be shipped empty and filled at the site of treatment, may be pre-loaded with medication before shipment to the site of treatment, or may be filled at an intermediate location. Whether pre-loaded or not, syringes are preferably transported and stored in secure containers that protect the syringes from contact with each other and from damage, often caused by compression from exterior forces.

It is common for medical professionals to prescribe treatment plans requiring multiple doses of injected medication according to a dosing sequence. A dosing sequence may require multiple injections of a constant dose of medication or a varying quantity, concentration or composition of medication. Patients and medical professionals must make every effort to adhere to the dosing sequence, verify compliance, and identify and record used and unused syringes. As a result, there is a need for a carton that holds and displays multiple syringes and allows a user to easily determine whether the medication in each syringe has been dispensed.

It is readily apparent that patients and medical professionals that need to dispense medication from a syringe may likely be engaged in other activities while utilizing the medications and as a result may only have the use of one free hand. This is particularly true during emergencies and surgery. Thus, there is a need for a carton that enables a user to easily retrieve a syringe from the carton and place an empty syringe back into the carton.

Despite these apparent needs, existing packages have several disadvantages. First, existing packages are expensive to fabricate and fill. Specifically, existing trays are fabricated from multiple pieces of material, require special machinery for fabrication, and require sealing during the assembly process. Trays formed from two or more pieces of material require that each piece be inventoried, raising costs and increasing the potential for inventory errors and complications. Some existing trays are thermoformed from petroleum-based plastic, which is harmful to the environment and generally not recyclable. In addition, because the existing trays are difficult to manufacture, the trays are typically pre-formed before shipment. Further, because pre-formed trays take up additional space when packaged for distribution to end-users, transportation costs are relatively higher. Thus, there is a need for an environmentally friendly carton that is inexpensive to produce and use. There is also a need for a carton that can be shipped before assembly and assembled on site without the need for special machinery. There is also a need for a carton with a reduced inventory requirement. Finally, since contents of existing trays are subject to damage and breakage during transport, there is a need for a carton that provides improved protection to its contents during transport.

SUMMARY

A carton and a method for producing the carton are disclosed herein. The carton is intended to hold contents such as syringes. The carton is generally formed by folding various panels of a blank made of a single construction. The carton comprises a rack with slots and apertures configured to hold the barrels and tips of syringes. The slots and apertures allow the barrel of the syringe to be viewed, which enables a user to quickly locate a specific syringe and identify the contents of the syringe. The slots and apertures securely hold syringes in place during shipment and storage, and insulate syringes from contact with each other.

The carton of the present invention also provides a disposal location for used syringes. Because the syringe barrels are visible when secured in the rack, users can easily determine whether a syringe has been used or unused. As a result, the carton helps organize a dosing sequence for users. Specifically, once the user retrieves a full syringe and administers a dosage, the empty syringe can be secured back in the carton. The user can then identify the next dosage in the sequence by locating the next full syringe in the carton. The carton may be labeled to provide additional information regarding dosage, such as the day of the month on which a particular dosage should be administered. Therefore, the carton enables increased adherence to a prescribed dosing regimen. When all syringes have been administered and returned to the carton, the lid of the carton can be securely closed to facilitate safe disposal.

The carton is fabricated using a minimal amount of material. A blank comprised of a single construction is cut and folded according to non-limiting steps including: cutting the blank out of a single sheet of material, forming apertures in the blank, folding panels of the blank to form the exterior surfaces of the blank, and folding panels of the blank to form a rack with slots and apertures. Flaps are provided to secure the carton. The blank is folded to form a closable lid with a flap for securely closing the carton.

Various materials and packaging mechanics can be used to produce the carton. The carton is environmentally friendly and inexpensive to produce and use. The carton provides improved protection for its contents. The carton can be shipped before assembly and assembled on site without the need for special machinery. Because the carton is formed from a single construction, only one unit must be inventoried.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description makes reference to the accompanying figures wherein:

FIG. 1A is a top plane view of a sheet of paperboard according to an embodiment of the present invention.

FIG. 1B is a top plane view of a carton blank in an unfolded position according to an embodiment of the present invention.

FIG. 2 is a top plane view of the blank with the side panels in a folded position across an angled fold line.

FIG. 3 is a top plane view of the blank with panels used to form a rack folded.

FIG. 4 is a top plane view of the blank with the panels used to form a rack further folded.

FIG. 5 is a top plane view of the blank with the top panel in a folded position.

FIG. 6 is a perspective view of the blank in the folded position depicted in FIG. 5.

FIG. 7 is a perspective view of the blank with the end flaps in folded positions to form a back wall and front wall of the carton.

FIG. 8 is a perspective view of the blank with the side flaps in a folded position.

FIG. 9 is a perspective view of the blank with the dust flaps folded in position to secure an accordion-like rack structure.

FIG. 10 is a perspective view of the assembled blank.

FIG. 11 is a perspective view of the assembled blank with the top of the carton in a secured position.

Other objects, features, and characteristics of the present invention, as well as methods of operation and functions of the related elements of the structure and the combination of parts, will become more apparent upon consideration of the following detailed description with reference to the accompanying drawings, all of which form part of this specification.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A detailed illustrative embodiment of the present invention is disclosed herein. However, techniques, methods, processes, systems and operating structures in accordance with the present invention may be embodied in a wide variety of forms and modes, some of which may be quite different from those in the disclosed embodiment. Consequently, the specific structural and functional details disclosed herein are merely representative, yet in that regard, they are deemed to afford the best embodiment for purposes of disclosure and to provide a basis for the claims herein which define the scope of the present invention.

None of the terms used herein, including “carton,” “blank,” “panel,” “top,” “bottom,” “end,” “side,” “edge,” “aperture,” “slot,” “dust flap,” “upward,” “downward,” “inward” and “outward” is meant to limit the application of the invention. Any reference to syringes is exemplary and is intended to encompass contents suitable for use with the disclosed carton. While solid bleached sulfate (“SBS”) paperboard is used in the preferred embodiment, it is merely exemplary and other materials may be used without departing from the principles disclosed herein. The terms are used to illustrate the preferred embodiment and are not intended to limit the scope of the invention. Similarly, the use of these terms is not meant to limit the scope or application of the invention, as the invention is versatile and can be utilized in many applications, as will be apparent. The following presents a detailed description of the preferred embodiment of the present invention with reference to the figures.

Disclosed herein is a paperboard carton and a method for making the carton out of a single piece of paperboard. A single piece of paperboard may be cut and folded by hand or by machinery to form a carton with a rack for securing objects such as syringes. Machinery may be used to automate part or all of the processes that will be described. SBS paperboard is preferred for its resistance to bacterial cultivation and its low susceptibility to particulate contamination.

Referring to FIG. 1A, shown is a rectangular section of paperboard 90 with exterior edge 92. In the preferred embodiment, the rectangular section is comprised of a single construction of paperboard and may be coated with a polymer to increase its resistant to tearing. In other non-limiting embodiments, durable paper, composite paper, cardboard, plastic, metal or other suitable materials, or a combination thereof, may be used. Alternatively, two or more pieces of material may be joined or otherwise merged to form a single construction to provide the basis for the steps disclosed herein.

Drawn onto the rectangular section of paperboard 90 are lines 94 delineating fold lines for use with the preferred embodiment. In the preferred embodiment, lines 94 are formed by stamping the rectangular section of paperboard with a die. In other non-limiting embodiments, lines 94 may be printed, creased, perforated, or otherwise demarcated, or a combination thereof. A blank is formed by cutting along the exterior edge of lines 94 and cutting out the apertures indicated by groups 96 and 98.

Referring to FIG. 1B, a blank 100 is shown in accordance with the preferred embodiment. Blank 100 comprises several panels depicted by predetermined fold lines and pre-break lines. The fold lines are preferably formed by scoring while the pre-break lines are preferably formed by a creasing operation. It should be appreciated that the fold lines and pre-break lines may be formed by other processes, including stamping and pressing. Scoring and creasing are provided to make it easier to fold and break the various panels during assembly of carton 300. As described in further detail below, blank 100 comprises primary panels that, upon application of the method disclosed herein, form the outer walls of carton 300 and inner structure panels that result in a rack for securing elongated items such as vials or syringes.

Blank 100 comprises a top panel 102, a bottom panel 106, side panel 112, side panel 114, end panel 104, and end panel 108. Blank 100 further comprises panel 126, panel 122A, panel 122B and panel 120 for forming a rack for securing elongated items. Top panel 102 and end panel 104 are aligned longitudinally and are connected at fold line 214. End panel 104 and bottom panel 106 are aligned longitudinally and are connected at fold line 212. Bottom panel 106 and end panel 108 are aligned longitudinally and are connected at fold line 210. End panel 108 and panel 126 are aligned longitudinally and are connected at fold line 208. Panel 126 and panel 122A are aligned longitudinally and are connected at fold line 206. Panel 122A and panel 122B are aligned longitudinally and are connected at fold line 204. Panel 122B and panel 120 are aligned longitudinally and are connected at fold line 202. Side panel 114 and bottom panel 106 are aligned laterally and are connected at fold line 222. Flaps 136A, 136B, and 136C are aligned laterally with side panel 114 and are connected to side panel 114 at fold line 226. Side panel 112 and bottom panel 106 are aligned laterally and are connected at fold line 220. Flaps 134A, 134B, and 134C are aligned laterally with side panel 112 and are connected to side panel 112 at fold line 224. End flap 116A and flap 136B are connected at fold line 212. End flap 116A and end panel 104 are aligned laterally and are connected at pre-break line 230A. End flap 116B and flap 136C are connected at fold line 210. End flap 116B and end panel 108 are aligned laterally and are connected at pre-break line 230B. End flap 116C and flap 134B are connected at fold line 212. End flap 116C and end panel 104 are aligned laterally and are connected at pre-break line 230C. End flap 116D and flap 134C are connected at fold line 210. End flap 116D and end panel 108 are aligned laterally and are connected at pre-break line 230D. Edge flap 118 is connected to top panel 102 at fold line 228. Slip 131 is formed by cutting a length of fold line 208 and is preferably at least as wide as the lateral width of edge flap 118. Aperture 132 is cut from end panel 108. Apertures 128 are cut from panel 126, and apertures 124 are cut from panels 122A and 122B. Dust flap 130A is connected to panel 126 along fold line 216, and dust flap 130B is connected to panel 126 along fold line 218.

In the preferred embodiment, pre-break lines 230A-D, designed to weaken the paperboard along the desired lengths, are formed by creasing blank 100. Pre-break lines, formed by creasing in the preferred embodiment, are useful in that they allow a person or machine to easily sever blank 100 along the pre-break lines when desired. Until broken, pre-break lines 230A and 230C help to preserve the flat form of blank 100 by holding together end panel 104 with panels 116A and 116C. Likewise, pre-break lines 230B and 230D help to preserve the flat form of blank 100 by holding together end panel 108 with panels 116B and 116D. In an alternative embodiment, pre-break lines 230A-D may be formed by scoring, cutting, stamping, pressing or other suitable process to facilitate the severing along pre-break lines 230A-D to enable the folding steps that will be described herein. In yet another alternative embodiment, pre-break lines 230A-D may be severed during formation of blank 100.

In its unassembled state, blank 100 lies flat and is only as thick as the thickness of the paperboard material. In this form, blanks retain a low profile and are easily stacked for packaging, storage and shipment. Folding the panels of blank 100 in a particular order produces a formed carton 300. For reference, a formed carton 300 is depicted in FIGS. 10 and 11.

The process for forming the carton of the present invention is described in detail in FIG. 1B through FIG. 9. Referring first to FIG. 1B, flap 136B and end flap 116A are folded over along fold line 200A. Flap 136C and end flap 116B are folded over along fold line 200B. Flap 134B and end flap 116C are folded over along fold line 200C. Flap 134C and end flap 116D are folded over along fold line 200D. After these four folds have been made, end flaps 116A-D are positioned above bottom panel 106, as depicted in FIG. 2.

The next step in the folding process will now be described with reference to FIG. 2. Panel 122B is folded over along fold line 204. After this fold has been made, panel 122B is positioned above panel 122A, and panel 120 is positioned above panel 126. The result is depicted in FIG. 3. As a result of this folding step, apertures 124 (depicted in FIG. 2) are formed as slots 125 (depicted in FIG. 3).

Next, referring to FIG. 3, end panel 108 is folded over along fold line 210. After this fold has been made, end panel 108, panel 126, panel 122A, panel 122B, and panel 120 are positioned above bottom panel 106. More specifically, when the entire blank is pressed flat in this position, end panel 108, panel 126, panel 120 and panel 122B are in contact with bottom panel 106. Also, while in this position, flap 130A and flap 130B are positioned above and in contact with side panel 114 and side panel 112, respectively. The result is depicted in FIG. 4. In the preferred embodiment, panel 120 is affixed to bottom panel 106 using adhesive. In alternative embodiments, panel 120 may be left unaffixed to bottom panel 106 or may be temporarily or permanently affixed using other suitable means commonly known in the art such as a hook and eye closure. The step of affixing panel 120 to bottom panel 106 may occur at any time without regard to the order of operations disclosed herein with respect to the preferred embodiment.

Continuing with FIG. 4, panel 104 is folded over along fold line 212. After this fold has been made, panel 104 is positioned above bottom panel 106, end flap 116A and end flap 116C, and top panel 102 is positioned above bottom panel 106, panel 122A, panel 126, and end panel 108. The result is depicted in FIGS. 5 and 6. In this position, the blank lies flat and can be easily stacked with other blanks for transportation, storage, and loading into machinery.

The next steps to complete construction of the carton are set forth with reference to FIG. 7 and FIG. 8. End panel 104 is rotated upward about fold line 212 and placed at an approximately right angle to bottom panel 106. End panel 108 is rotated upward about fold line 210 and placed at an approximately right angle to bottom panel 106. Side panel 112 is rotated upward about fold line 220 and placed at an approximately right angle to bottom panel 106. Likewise, side panel 114 is rotated upward about fold line 222 and placed at an approximately right angle to bottom panel 106. Dust flap 130A and dust flap 130B (not labeled) are rotated upwards and placed at an approximately right angle to panel 126.

In the preferred embodiment, end flap 116A and end flap 116B are affixed to end panel 104 using adhesive. In alternative embodiments, end flap 116A and end flap 116B may be left unaffixed to end panel 104 or may be temporarily or permanently affixed using other suitable means. The step of affixing end flap 116A and end flap 116B to end panel 104 may occur at any time without regard to the order of operations disclosed herein with respect to the preferred embodiment.

Next, with reference to FIG. 9, panel 126 is rotated downward about fold line 131 with respect to end panel 108, and panel 126 and panel 122A are positioned at an approximately right angle at fold line 206. Panel 122A and panel 122B (not shown) are positioned at an approximately right angle at fold line 204. Dust flap 130A and dust flap 130B (not visible) are positioned against side panel 114 and side panel 112, respectively. In the preferred embodiment, dust flap 130A and dust flap 130B are affixed to side panels 114 and 112, respectively, using adhesive. In alternative embodiments, dust flap 130A and dust flap 130B may be left unaffixed to side panel 114 and side panel 112 or may be temporarily or permanently affixed using other suitable means. The step of affixing dust flaps 130A-B to side panels 114 and 112 may occur at any time without regard to the order of operations disclosed herein with respect to the preferred embodiment.

Next, with reference to FIG. 10, panel 136A, panel 136B, and panel 136C are folded over along fold line 226 so that panel 136A, panel 136B, and panel 136C are positioned at an approximately right angle to side panel 114 (not shown) and parallel with bottom panel 106. Panel 136A, panel 136B, and panel 136C are folded over along fold line 224 so that panels 134A-C are positioned at an approximately right angle to side panel 112 and parallel with bottom panel 106. Edge flap 118 is folded inward along fold line 228 and positioned an approximately 90 degree angle with respect to top panel 102. Once blank 100 has been assembled according to the foregoing steps, the result is carton 300 as depicted in FIG. 10. With top panel 102 raised as shown, objects such as syringes may be loaded into and removed from carton 300.

With reference to FIG. 11, carton 300 may be closed by rotating top panel 102 downward along fold line 214 and inserting edge flap 118 into the gap formed by aperture 132 and slip 131. In this configuration, carton 300 is secured in the closed position. Aperture 132 provides access to edge flap 118, allowing a user to easily release edge flap 118, lift top panel 102 and thereby open carton 300.

In its constructed form, carton 300 contains one or more slots 125 and apertures 128. Although multiple slots 125 and multiple apertures 128 are depicted in the figures, it should be understood that one or more slots and apertures may be disposed in a carton without departing from the principles disclosed herein. Panel 126, panel 122A, and panel 122B form a rack in which slots 125 and apertures 128 may accommodate elongated items such as, for example, vials or syringes. It is contemplated that a slot 125 can hold the barrel of a syringe while an aperture 128 can hold the tip or cap of a syringe. The configuration of panels, slots and apertures enables a user to view the contents of vials and syringes. Specifically, because the barrel of the vial or syringe is exposed, a user can view any upward-facing labels and can view the contents of a clear vial or syringe. The configuration of panels, slots, and apertures in the carton also allows easy access for loading and unloading the carton with vials and syringes. The rack formed by panel 126, panel 122A and panel 122B, along with slots 125 and apertures 128, allows a user to lift a syringe in carton 300 by the barrel of the syringe, thereby minimizing the risk of releasing a safety trigger or disturbing the plunger rod of the syringe.

In the closed position, carton 300 may be readily stacked with other similar cartons or other objects. The closed position also prevents light from reaching the contents of the carton, thereby reducing any effects light may have on the contents. Carton 300 provides safety and security for its contents during transportation. Information can be printed on any visible surface of carton 300. Preferably, information is printed on the interior or exterior surfaces of top panel 102 and the exterior surfaces of bottom panel 106, end panel 104, end panel 108, side panel 112, and/or side panel 114. Blank 100 and carton 300 may be fabricated using opaque, transparent, or translucent materials. It should be appreciated that transparent and translucent materials may allow a person to see the contents of carton 300, even when it is in the closed position. Additional materials, coatings, labels, or other additional materials may be added to carton 300 without departing from the principles disclosed herein. For example, tape, seals, or other materials may be added to the interior or exterior of carton 300 to provide additional security and prevent or indicate tampering or theft.

It should be appreciated that top panel 102 and edge flap 118 are disclosed in accordance with the preferred embodiment. In an alternative embodiment, top panel 102 and edge flap 118 may be omitted to provide an open-top carton. Alternatively, a completely separate lid may be provided for use with the carton and may comprise one or more edge flaps. Also, one of ordinary skill in the art will readily recognize that shrink foil, paper bands, and packaging materials may be used in conjunction with the disclosed carton.

While the present invention has been described with reference to the preferred embodiment, which has been set forth in considerable detail for the purposes of making a complete disclosure of the invention, the preferred embodiment is merely exemplary and is not intended to be limiting or represent an exhaustive enumeration of all aspects of the invention. The scope of the invention, therefore, shall be defined solely by the following claims. Further, it will be apparent to those of skill in the art that numerous changes may be made in such details without departing from the spirit and the principles of the invention. It should be appreciated that the present invention is capable of being embodied in other forms without departing from its essential characteristics. 

What is claimed is:
 1. A carton, comprising: a bottom panel; a front panel coupled to the bottom panel; a back panel coupled to the bottom panel; a first side panel coupled to the front panel and the back panel and the bottom panel; a second side panel coupled to the front panel and the back panel and the bottom panel; and a rack comprising at least one aperture and at least one slot.
 2. The carton of claim 1, wherein said carton comprises a single construction.
 3. The carton of claim 2, wherein said carton comprises one of the following: paperboard, durable paper, composite paper, cardboard, plastic, and metal.
 4. The carton of claim 1, further comprising: a top panel; and an edge flap.
 5. The carton of claim 4, further comprising at least one slip adapted to receive the edge flap.
 6. The carton of claim 1, further comprising one or more side flaps.
 7. The carton of claim 6, wherein the one or more side flaps are affixed to at least one of the first side panel and the second side panel.
 8. The carton of claim 1, wherein the rack is affixed to the bottom panel.
 9. A method of producing a carton, comprising: providing a blank comprising a bottom panel, a front panel, a back panel, a first side panel, a second side panel, at least one large aperture disposed in the front panel, and at least one small aperture disposed in the front panel; performing the following steps in any order: folding the blank to position at least one section of the front panel substantially orthogonal to the bottom panel; folding the blank to position at least one section of the back panel substantially orthogonal to the bottom panel; folding the blank to position at least one section of the first side panel substantially orthogonal to the bottom panel; folding the blank to position at least one section of the second side panel substantially orthogonal to the bottom panel; folding the blank to position the at least one large aperture and the at least one small aperture within an area bounded by the bottom panel, the at least one section of the front panel, the at least one section of the back panel, the at least one section of the first side panel and the at least one section of the second side panel.
 10. The method of producing a carton according to claim 9, further comprising: providing a sheet of material; and cutting the sheet of material to produce the blank.
 11. The method of producing a carton according to claim 9, further comprising: folding the blank so that the at least one large aperture forms a slot; and folding the blank so that the at least one small aperture is aligned with the slot.
 12. The method of producing a carton according to claim 9, further comprising: affixing together at least two of the bottom panel, the front panel, the back panel, the first side panel, and the second side panel.
 13. A carton, comprising: a bottom panel; a front panel coupled to the bottom panel; a back panel coupled to the bottom panel; a first side panel coupled to the front panel and the back panel and the bottom panel; a second side panel coupled to the front panel and the back panel and the bottom panel; a rack comprising at least one aperture and at least one slot; and wherein the carton is manufactured of material selected from the following: paperboard, durable paper, composite paper, cardboard, plastic, and metal.
 14. The carton of claim 13, wherein the carton comprises a single construction.
 15. The carton of claim 13, further comprising: a top panel; and an edge flap.
 16. The carton of claim 13, further comprising at least one slip adapted to receive the edge flap.
 17. The carton of claim 13, further comprising one or more side flaps.
 18. The carton of claim 17, wherein the one or more side flaps are affixed to at least one of the first side panel and the second side panel.
 19. The carton of claim 13, wherein the rack is affixed to the bottom panel. 